What Did You Do Today 2025

[DalboyParticipant @dalboy]

Thank you, Diogenes and Vic.

That rack is a great idea I have been looking for a design for racks and that fits the bill just right, may have to steal that if I can.

 

[VicParticipant @vic]

Yes of course, help yourself. The overall size is 240 x 125 with 50 and 55mm long spacers. I’ve no idea what plastic the chopping boards are but they cut very nicely.

[Richard SimpsonParticipant @richardsimpson88330]

Fitted and test run a new Automatic Boiler Control system into my Hereward and gave it a test run on the bench.  The big improvement of the ABC2 over the old ABC is that the control of the gas valve is now proportionate.  Pretty cool watching the gas valve move to a position proportionate to boiler pressure.

[JasonBModerator @jasonb]

Richard, does it do that automatically? Reducing the flame when just ticking over and then increasing as the engine calls for more steam. I was going to ask the other day when I saw the box of tricks.

What other functions are there, can it monitor water level and activate a bypass valve to keep water withing a set levels?

[duncan webster 1Participant @duncanwebster1]

What’s a Hereward? Write up of your ABC for ME&W required!

[Richard SimpsonParticipant @richardsimpson88330]

I’m actually in the process of doing a review of the product for a Model Boats Magazine article so you will be able to read the full review in around the February 2026 edition.

In a nutshell the ABC does two functions.  First it controls water level using a level sensor fitted to the sight glass.  This sends a signal back to the unit and is used to either operate a two way servo controlled valve on an engine driven water pump outlet to either dump back to the feed tank or to feed the boiler or it is used to stop or start a feed water pump.  The sensor is temperature compensated and incorporates a delay to help dampen down the effects of the water rising and falling with the movement of the boat.

The second function is to control the boiler pressure.  This it does by using a pressure sensor in the steam space of the boiler, its actually a temperature sensor but this is directly proportional to the pressure within the operating range.  This again goes back to the ABC and is used to control a servo operated gas valve.  This latest version of the ABC is an improvement on the original as it doesn’t just switch from full flame to pilot flame but it positions the valve proportionally between full flame and pilot flame according to the boiler pressure and it can also be arranged to completely shut off the gas either from the transmitter via a switcher unit, or as a result of the feed tank being empty.  I can’t include pictures as they are earmarked for the article.

Hereward is the name of the boat.  The original plan was called the Wide-A-Wake and being interested in my local history, which includes the activities of Hereward The Wake, I decided to call the boat Hereward.

[JasonBModerator @jasonb]

Thanks for the detail

On of our members as well as making model aero engines also likes a bit of boating. This is a link to Ramon’s Wide a Wake build complete with engien and boiler building.

[Richard SimpsonParticipant @richardsimpson88330]

Thanks Jason, I have seen that thread in the past and have always thought it to be not only the best example of a build of this model but the best documented.  That thread is a joy to read through and the level of skill put into the boiler refurbish and the engine rebuild is quite stunning.  My example is of cheats and shortcuts wherever I could use one, Ramons is pure scratch building at its very best at every step of the way.  I can’t believe he even turned the spokes of his own steering wheel and built the wheel from scratch!

Its also good to see that he still answers posts on that thread even this year so good to see he is still with us and still contributing.  If he reads on here as well, Ramon there are very few people who can work in wood and metal at the level you have achieved.  Your example of Wide-A-Wake is art and an absolute joy to behold.  You have my greatest admiration.

[Nigel Graham 2Participant @nigelgraham2]

Wire-brushed the ash-pan from the club’s “Wren” locomotive, and gave it a quick spray of outdoor-grade black paint intended to stick to rust. (Do not use in bright sunshine”, the label says. Errr, it’s intended for painting outdoor metalwork.)

I have the pan at home with a view to making a replacement as it’s practically worn out – so spent much of yesterday evening producing an “Alibre” drawing of its basic form. It is not quite as Ken Swan designed, hence my drawing of what was actually fabricated. Difficult as a 3D image despite its apparent simplicity as an open-ended tray. It is an “assembly” of three “parts”, of thin sheet material, and placing the locating constraints was not at all easy. I can’t add the two cross-bearers that support the grate, but otherwise I won the fight before cocoa time.

Back to today…

– Repaired the closing thread on an ER32 collet-chuck that had become virtually unuseable. I was unable to determine the fault even with a magnifying-glass, but very careful hand-chasing with a single-point tool won the day (q.v. in General Questions).

Then after dinner….

– Cleared the accumulating rammel around the Denbigh H4 horizontal mill so I could start “designing” the necessary frame work etc. for driving this antique machine intended for line-shaft connection, at around 70 to 100 rpm from a 1350rpm motor.

Then tea-time….

– Started to draw the new version of the eccentric-rods for my steam-wagon engine. Gave up after unending, invisible sketch errors with unintuitive names, no indications where they are on the sketch, and the “Analyze” [sic] tool switched off. (This is in Alibre ‘Atom’ – I believe the analysis is active in Alibre’s fuller editions.)  To hell with it: I’ll create an orthographic TurboCAD drawing… or a manual sketch. I’m never going to publish plan sets for anything, nor create CAD/CAM files.

Closed that and came on here!

[Nigel Graham 2Participant @nigelgraham2]

I don’t suppose I am rare in having Magpie tendencies and I really cannot recall where and when I’d acquired a tote-tray of assorted end-mills and slot-drills, but finally digging them out, cleaning and roughly sorting them, kept me out of mischief for a couple of hours or so!

Two or three have Weldon or equivalent shanks: useable in an R8 split collet or a lathe chuck.

Most have screwed shanks and are of sizes I can use.

Many were obviously used but I can sharpen at least the ends, on my Hemingway Kits Worden T&C Grinder.

A useful number seem unused, coated with a thick layer of wax.

Very few are too large for my milling-machine – I may try to find them new homes.

I condemned only about five, small-diameter, cutters as “scrap” (broken ends or strange re-grindings)… material for boring-bar bits, thread-profile lathe tools, and the like.

 

I counted ’em…. a hundred! I reckon they will see me out. Not to mention saving a lot of money.

……

Also determined the most likely worm for the table-feed on the Denbigh mill, using what measurements I could make, and Ivan Law’s book on Gears & Gear-cutting (in the Workshop Practice series).

This, if I am right, gives a worm pitch of very slightly over 1/4″ pitch, and a lot of figure-juggling and calculator button-pressing to find the nearest change-wheels to use on my Harrison lathe (1/4″ lead screw). Mr. Law’s way to calculate CW trains of regular wheels for very odd pitches is too difficult for me. I simply used iterations based on inspired guesses, to arrive at a pitch within about 0.002″ of correct: near enough for what I can hope to finish it to!

Why? The worm, Cardan-type drive-shaft and connection to the machine spindle, are all missing.

[Nigel Graham 2]

On Nigel Graham 2 Said:

 

– Started to draw the new version of the eccentric-rods for my steam-wagon engine. Gave up after unending, invisible sketch errors with unintuitive names, no indications where they are on the sketch, and the “Analyze” [sic] tool switched off. (This is in Alibre ‘Atom’ – I believe the analysis is active in Alibre’s fuller editions.)

Nigel the Analyze tool runs on exiting a sketch – unless you have turned it off in system options!  There is a check box for ‘automatically analyze sketch’ in System options -> Parts/Assemblies -> Sketching

[DiogenesParticipant @diogenes]

Worth checking ‘old‘ end mills/slot drills to classify the ‘edge presentation’

– it’s not uncommon to find many that have very conservative neutral angles, made to bludgeon their way across vast iron castings for business owners with short arms and deep pockets..

..they aren’t kind to ‘lighter’ machines and don’t play nicely with most other materials – it’s easy to forget how common CI components were 1950-1980..

I don’t buy them any more!

 

 

[Nigel Graham 2Participant @nigelgraham2]

David –

Thankyou. Yes, I know it does. It is active, but it does not help me unless the mistake is obvious on close inspection, such as some line left un-trimmed, or perhaps a tangent that isn’t. (Tried using the Tangent constraint: can’t – it would “over-constrain” the sketch.)

If the errors are invisible the message may just as well say merely, “Your sketch is all rubbish”.

If I select “Ignore” then “Extrude [cut]” it gives me a second message that just tries to blind me with computer science to remind me how incompetent I am.

.

Diogenese –

I did not say these cutters are “old” historically, or of old forms. They came from some workshop clearance but I have had them for some years and have only just stirred myself to do anything with them.

The collection basically fall into three types:

– A very few that have been reground, some well, some at strange angles for specific tasks, some just badly;

– ones simply needing light resharpening;

– and ones that have not been used.

Apart from a few unusual ripping end-mills with “patent” edges – I judged the oddest is perhaps for soft materials that would choke fine serrations – none are at all of unconventional geometry.

Apart of course from the few “modified” or cack-handedly “sharpened” by their previous owner using a scythe-stone.

 

As for short arms and deep pockets, yes that might apply to the manufacturer, but also and more so, to the customer driving hard bargains!

[DalboyParticipant @dalboy]

Spent the first part of today doing little bits and pieces on the Farm Boy no photos as making gaskets and other small finishing jobs.

Then this afternoon mounted the faceplate for the 5C collet holder as I had already started the mounting to the lathe side which I did post about quite a few days ago(OK weeks ago)

Onto the chuck mounting side I did have to turn the outer diameter with a boring bar and the lathe in reverse, it worked very well. Tomorrow I will get around to drilling and tapping the thread. I have marked the first hole position with a transfer punch once drilled and tapped I will do the same to the remaining two holes.

[DalboyParticipant @dalboy]

Finished the backplate for the 5C collet chuck, managed to get it within 0.0005″ (don’t ask me how but pleased with that)

The lathe spindle has a “0” mark on it so i also marked the backplate to make sure I fit it the same every time

[AStroudParticipant @astroud]

I put some finishing touches to my rotary engine which is based on the Coomber design, the main differences being I used a true circle for the ring as I could not understand why the Coomber used an off circle which looked tricky to make and the 2 cylinders work independently and have separate pistons and conrods. I am thinking of trying some nylon rollers as it is a bit clattery when it runs.

https://youtu.be/iVgsvn_kNdE

 

[Nigel Graham 2Participant @nigelgraham2]

Quite the busy bee today!

A morning session with the regular drivers of our club’s narrow-gauge outline loco, a Ken Swan interpretation of the Kerr-Stuart ‘Wren’, to obtain consensus on moving the pressure-gauge and vaccum-brake valve to more visible and accessible positions.  Despite the relatively high cab roof taller drivers have problems seeing the gauges, and we all found the valve, which is a later, club, addition neither KS nor KS “OEM”, awkward to reach.

Back in my own shed, and entertained by Radio Three’s salutation of a certain 200-year anniversary, I improved access for manoeuvering one very heavy and unwieldy unfinished steam-wagon, did some more head-scratching over how to power an antique horizontal milling-machine – and unhappily discovered I’d damaged my Myford 7’s screw-cutting gearbox more seriously than I had thought.

That damage was when working very close to a Myford collet, which is directly held in the spindle taper. Using power-feed I was so careful to avoid running the tool into the collet I failed to spot the lead-screw shield was approaching the gearbox until everything suddenly came to an undignified stop. I found this had broken two or three gear teeth, but investigating again today with a view to obtaining new wheels showed worse damage: a slightly bent output shaft – the pinion outside the box visibly oscillates.

[Nigel Graham 2Participant @nigelgraham2]

Started cutting a keyway 10mm wide by about 8mm deep the full length of the workpiece….

…. Which is a 2″ diameter solid steel bar a bit longer than the Myford VMC milling-machine table, significantly longer than the maximum travel, and I want the keyway sustantially in line for the entire length.

Any guesses as to how I am doing this so the channel stays constant and straight, as far as I can manage, with four lengthways movements to bring the next stage in range?

 

It is for the over-arm for my Denbigh milling-machine. With only a single, round-section arm there is no obvious way to maintain constant centering of the drop-bracket when moved axially, at least not on mine whose arm appears non-original.

 

Oh… the 200th Anniversary cited in my previous post.

Actually two significant ones this year. One of course is that of the first passenger train, on the Stockton-Darlington Railway.

The other? The invention in France of Louis Braille’s system to allow the blind to read by patterns of raised dots – and importantly not only text but also music.

[Andrew CrowParticipant @andrewcrow91475]

Hi Nigel, would it be possible to put a couple of tapped holes in the opposite side of the bar to the keyway. If so it could be bolted to a sturdy steel plate which could then be slid along the table against some tenons in one of the tee slots which would maintain position.

Andy

[DiogenesParticipant @diogenes]

Nigel, don’t bother – the overarms on these small horizontals are normally able to ‘float’ onto the end of the arbor and find their own ‘happy place’..*

If you key it there’s a chance of it binding/pressing on the end or one side of the arbor and that won’t end happily at all..

*EDIT – i.e. set it up, slide the overarm into place, rotate a couple of turns by hand to make sure it is ‘snug-but-free’ and lock it off.

[Nigel Graham 2Participant @nigelgraham2]

Thank you for that.

The overarm has a short, reduced shank turned eccentrically to the bar, and this spigot held a cast-iron bracket of curious form, I think was re-using some component from a totally different machine. So it was possible to locate the bracket with the bearing centre anwhere within a circle more than half an inch diameter!

This bracket had been locked to other arm by a large set-screw, and had cracked across the eye, or rather thin wall for that purpose. It had been welded, and even used the mill with this but only for a large radial-drilling task. In time the weld failed and the broken off part is now long-lost.

My aim is to make a new drop-bracket secured to the major diameter, as normal for these machines; but the point of the keyway is to obviate having to re-centre the arbor journal each time I move the arm in or out. Rather as on those round-column mill/drills, when you raise or lower the head.

 

[DiogenesParticipant @diogenes]

Not sure what you mean about ‘re-centreing the arbor’..

The drop bracket should only support the end of the arbor, which is aligned by it’s own taper.

It shouldn’t need to fulfil any active ‘positioning’ role, and if it does, then the arbor is bent or not seating correctly.

 

 

[JasonBModerator @jasonb]

A bit of faceplate work made a pleasant change from the usual chucks and collets.

Boring out the far end of the Robinson HA waterjacket ready for the liner. 48mm dia x 100mm deep into the casting.

This is the neat view

And the not so neat one where I have added some clamps and a selection of carefully calculated balance weights!

I decided not to push my luck and only took it upto 120rpm.

[Nigel Graham 2Participant @nigelgraham2]

An impressive set-up, Jason!

 

Diogenes –

What I feared is if the drop-bracket journal is not exactly concentric with the spindle it will try to push the arbor sideways, risking e.g. wear on the tapers, eccentric wear on the drop-bracket bearing, or inaccurate cutting.

I thought most horizontal milling-machines have two over-arms, or dovetail heads as on the Centec and Aciera; but little ones like the Denbigh H-series made for l

light production work such as slotting screws and cutting spanner-flats, needed only a single, round arm.

Numbers H1 to H3 had only rack-and-pinion table feeds operated by a lever, for semi-skilled batch work. Mine is the top-of-the-range H4, with 1/6-inch pitch leadscrew.

I need make a new drop-bracket, whose two apertures have to be at exactly the right centre distance.

Then when the machine is set up, the journal has to be set concentrically with the spindle, and this appears rather a gamble.

My plan had been fit the arm with keyways in both front and back bearers, and the bracket; then finish-bore the lower journal in the bracket by clamping that rigidly to the table with the arm free to slide, so to feed the bracket inwards with the normal cross-feed. I used this successfully when fitting an over-arm and drop-bracket to a Centec, and had to make the bracket.

The Denbigh parts may be too heavy for this process, of course, with the feed screw below the rest of the arrangement. A better alternative may be to key only the arm and bracket, and feed the bracket along the arm.

[bernard towersParticipant @bernardtowers37738]

Trip to Forncett Steam Museum Model Engineers Day today on the old bike and very nice too. Several traction engines which have a road run and as well as full size in steam there were model rail layouts/steam plants/internal combustion/model boats and 3D printing going on upstairs with a good supply of coffee and cake!. The ride home wasn’t bad either. Where were you Noel?.

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